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2012 Chassis Cab PTO Operation & Installation Guide
06/19/2012
PTO General Guidelines
PTO PTO
GENERAL
GeneralGUIDELINES
Guidelines
The Dodge Ram 3500/4500/5500 Chassis cab models equipped with diesel engines that have the
PTO prep option (LBN) have the capability of mounting and controlling a PTO.
The gasoline powered models do not have PTO capability.
The Dodge Ram 3500/4500/5500 Chassis cab models equipped with diesel engines that have the
The Aisin AS68RC Automatic transmission can use devices up to 35 HP and 130 ft-lbs torque.
PTO prep option (LBN) have the capability of mounting and controlling a PTO.
Chelsea 270 or 252 series fit this transmission. Muncie CS6 series fit this transmission. There is
The gasoline powered models do not have PTO capability.
no difference in how PTO and pump mount between 4x2 and 4x4 automatic models.
The Aisin AS68RC Automatic transmission can use devices up to 35 HP and 130 ft-lbs torque.
The G56 manual transmissions are limited in power output only by the PTO manufacturers’
Chelsea 270 or 252 series fit this transmission. Muncie CS6 series fit this transmission. There is
maximums. Chelsea 442 (deep mount) series fit this transmission, however on 4x4 models this
no difference in how PTO and pump mount between 4x2 and 4x4 automatic models.
PTO is very close to the front driveshaft . Muncie Alpha series fits this transmission.
The G56 manual transmissions are limited in power output only by the PTO manufacturers’
Pump
maximums. Chelsea 442 (deep mount)
seriessizes
fit this transmission, however on 4x4 models this
ThePTO
automatic
transmission
models
have been
test fitAlpha
with series
17 GPM
size single pumps and
is very close
to the front
driveshaft
. Muncie
fitsrated
this transmission.
tandem 11 GPM rated pumps. While these larger pumps have limited clearance to the exhaust
Pump sizes
system and many people have mentioned this as a concern, it should be noted that the exhaust
The automatic transmission models have been test fit with 17 GPM rated size single pumps and
pipe in the PTO area is a double walled pipe which provides significant heat insulation
tandem 11 GPM rated pumps. While these larger pumps have limited clearance to the exhaust
properties. In fact, in our extreme heat PTO testing in over 100 degree F Fahrenheit
system and many people have mentioned this as a concern, it should be noted that the exhaust
temperature we never exceeded 200 degree F on the PTO, pump or hoses.
pipe in the PTO area is a double walled pipe which provides significant heat insulation
The manual transmission models are as follows: The 4x2 models have no particular packaging
properties. In fact, in our extreme heat PTO testing in over 100 degree F Fahrenheit
limitations with respect to direct mount pumps. The 4x4 models are limited by the location of
temperature we never exceeded 200 degree F on the PTO, pump or hoses.
the front driveshaft to approximately a standard 11 GPM rated pump (although larger pumps
The manual transmission models are as follows: The 4x2 models have no particular packaging
may have been successfully fitted in the field). However, some customers have had success
limitations with respect to direct mount pumps. The 4x4 models are limited by the location of
using bent axis piston pumps (mounted forward) to get substantially higher flows.
the front driveshaft to approximately a standard 11 GPM rated pump (although larger pumps
If you have specific PTO and pump fitment questions and can provide the actual PTO and pump
may have been successfully fitted in the field). However, some customers have had success
combination, we can test fit it and provide pictures and instructions on how to install your
using bent axis piston pumps (mounted forward) to get substantially higher flows.
specific combination.
If you have specific PTO and pump fitment questions and can provide the actual PTO and pump
combination, we can test fit it and provide pictures and instructions on how to install your
PTO Limitations
specific combination.
PTO Limitations
New information: click here to see the bulletin
Please read this information carefully and call us with any questions before you order a vehicle so you
PTO
Limitations
understand the specific
capabilities
of our PTO system.
Please
read
this information
carefully
call us
with not
anyengine
questions
before
youthis
order
a vehicle
The
Automatic
transmission
PTO isand
turbine
driven
driven.
What
means
is thatso you
understand
the
specific
capabilities
of
our
PTO
system.
the PTO will work only with the stationary mode in park, or in mobile mode with the vehicle
moving at approximately 7 mph and above or in neutral. Because of this the PTO system is not a
The Automatic transmission PTO is turbine driven not engine driven. What this means is that
suitable system for vehicles like: snow plows, autoloader wreckers, or dump trucks if they are
the PTO will work only with the stationary mode in park, or in mobile mode with the vehicle
used to dump and spread at a crawling speed. These vehicles are more effective with an
moving at approximately 7 mph and above or in neutral. Because of this the PTO system is not a
engine driven ‘clutch pump’ type hydraulic pump. Alternatively, Parker-Chelsea makes a
suitable system for vehicles like: snow plows, autoloader wreckers, or dump trucks if they are
product called Stored Energy Management System (SEMS) that allows such applications to
used to dump and spread at a crawling speed. These vehicles are more effective with an
function.
engine driven ‘clutch pump’ type hydraulic pump. Alternatively, Parker-Chelsea makes a
The size and package space do not allow for components driven by a driveshaft from a PTO on
product called Stored Energy Management System (SEMS) that allows such applications to
our trucks. The automatic transmission models have exhaust system components in the way
function.
that cannot be relocated because it will effect emissions compliance. The manual transmission
models have either the transfer case (4x4) or the transmission crossmember in the way.
The manual transmission has the capability to support a split shaft PTO. The automatic
transmission model does not support a split shaft PTO because the transmission cannot be held
in direct drive gear.
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PTO Quick Start Information
This section will give you specific instructions on how to wire a PTO on the 2011 and2012
3500/4500/5500 models. The information is tailored toward those familiar with PTO installation on the
2007 to 2010 but can be equally helpful to anyone installing a PTO.
Wire Locations
The white connector under the dash contains the following connections.
1. K425 (Orange/brown) PTO (non remote) switch. Connects to V937 to put the vehicle into PTO
mode.
2. V937 (Violet/brown) PTO switch return.
3. F425 (Pink) Remote PTO switch. Connects to V937 in place of F425 if remote or learned single
set speed is needed.
The mate to this connector is the smaller black connector that comes in the upfitter kit plastic bag.
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The larger gray connector in this bag connects to a mating connector to the left of the white
connector in the photo above. Use this connector to provide you circuit F922 (Pink/yellow).
typically used for 12V+ ignition feed power for the PTO indicator light.
1
3
2
4
06/19/2012
This
The light gray connector under the hood shown in the figure above (below the dark gray connector)
behind the auxiliary PDC contains the following connections. The Pin numbers below are molded into
the surface of the connector. The wires that plug to this connector are also in the upfitter kit plastic bag.
1. K427 (orange/light green) This wire, when connected to the mating K427wire on the next
page, will cause pin 2 to have 12 V output.
2. F928 (pink /tan) Switched 12 v output that connects to the hot shift solenoid.
3. Z907 (black/brown) ground
4. G 425 (violet/yellow) PTO indicator light feed. This wire connects to the PTO pressure
switch and feeds through the dash to the gray under dash connector mentioned above.
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Behind and below the auxiliary PDC are the following two (of five wires in 2012) wires coming out of the
main wiring harness.
The figure above shows these two wires after they are uncoiled and extended from their as shipped
position. Also the ends will be terminated with black heat shrink wrap. It may be necessary to unclip
the auxiliary PDC from its bracket and rotate it slightly forward to gain easy access to these two wires.
1. K427 (Orange/ Lt. Green) connects to the mating K427 connector in 1 of the light gray
connector.
2. T 754 (Dark Green/Grey) Hard wired remote start wire. See hard wired remote start
instructions at this link. http://www.rambodybodybuilder.com/2012/docs/cc/adssi.pdf
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PTO Operation
The 3500/4500/5500 Ram Chassis Cab vehicle, when equipped with either the automatic
Aisin 6spd or manual G-56 6spd transmissions, will allow for an aftermarket upfit with a
transmission driven PTO (power take off). The customer will have the ability to operate
the PTO in either a “stationary” or “mobile” mode. The vehicles will be factory set to the
“stationary” mode. In order to select the “mobile” mode a Chrysler Group LLC
Dealership is required to modify the vehicles settings using their proprietary Dealer
service tool. Under normal operation the vehicle will go to a 900 rpm when PTO is
engaged. By utilizing the cruise switches the idle speed can then be adjusted to between
900 and 2000 rpm’s.
Stationary Mode
This feature interacts with the transmission to utilize an auxiliary shaft to drive
equipment. Activated by a switch inside the cab, this feature operates only when the
vehicle is stationary. The input is switched to ground.
Once active, the engine speed increased by holding the RES ACCEL button on the
steering wheel or decreased by holding the COAST button.
Stationary PTO is available only when the vehicle is stationary. When the truck is
equipped with an automatic transmission, it must be in Park and the service brake must
be released and functional. When the truck is equipped with a manual transmission, the
Parking Brake must be Set and the service brake must be released and functional.
To operate the PTO in this mode the vehicle must meet the following conditions:
Be in “park” position ( vehicles equipped with automatic transmission)
Upfitter provider (on/off) switch has been activated
Parking brake applied (vehicles equipped with manual transmission)
Clutch not depressed (clutch interlock switch)
Vehicle must be running
No transmission, engine, accelerator, brake or clutch switch faults present
PTO must be correctly installed using the vehicle provided circuits
The customer has the choice to operate the PTO by utilizing the cruise control switches
or by utilizing a remote control (provided by the PTO supplier). To operate the feature
using the cruise control switches the customer must first activate the up fitter provided
on/off switch. The vehicle is now in the PTO mode and is ready for use. In order to
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increase or decrease the engine idle speed, to optimize the PTO function, the “accel” and
“decel” cruise switches can be used respectively.
To disengage PTO operation and return to “standard vehicle operation” simply turn the
up fitter provided on/off switch to the off position.
To operate the PTO via a remote switch the customer must make sure the above
conditions are met. It is vital for proper operation that the PTO and remote have been
installed correctly paying special attention to ensure the vehicle provided wiring has been
connected properly. This is the responsibility of the installer of the PTO and
switches/remote system. It is the responsibility of the PTO manufacturer to ensure that
their electrical (switches and remote) system is compatible with the vehicle’s electrical
architecture and software functionality.
Mobile Mode
This feature interacts with the transmission auxiliary shaft. The feature is activated by a
switch (closed to ground) in the cab after selected by a service tool. When active, this
feature limits engine speed and road speed to calibrated values.
When this feature is selected stationary PTO and Remote PTO features are not available.
To operate the PTO in this mode the vehicle must meet the following conditions:
Dealer selected “mobile” mode activated via Dealer proprietary service tool
Upfitter provider (on/off) switch has been activated
Vehicle must be in “park” or “drive” position (vehicles equipped with automatic
transmission)
Parking brake must not be applied
Clutch not depressed (clutch interlock switch)
No transmission, engine, accelerator, brake or clutch switch faults present
Vehicle must be running
PTO must be correctly installed using the vehicle provided circuits
The customer may choose to use the PTO while the vehicle is moving. To do so the PTO
function must be activated prior to taking the vehicle out of “park”. This is accomplished
by activating the up fitter provided PTO on/off switch. At this point the customer may
place the vehicle in a forward or reverse gear and have PTO operation.
To disengage PTO operation and return to “standard vehicle operation” simply turn the
up fitter provided on/off switch to the off position.
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Remote Stationary mode
This feature interacts with the transmission to utilize an auxiliary shaft to drive
equipment. Activated by a switch outside of the cab, this feature operates only when the
vehicle is stationary. The input is switched to ground.
Once active, the engine speed is changed when the switch changes from Off (open
circuit) to On (closed to ground) or toggled in less than ½ second. Toggling the switch
On-Off-On triggers the engine to change to the next calibrated engine speed. This can be
repeated for up to five engine speed settings. Repeated toggles cycles through the engine
speed 1-2-3-4-5-1-2 and so on.
Remote PTO can be calibrated for one to five selectable engine speeds. The engine
speeds are also calibrated.
Remote PTO feature has a higher priority than Idle Up. If the Remote PTO feature is
active the Idle Up switches are ineffective. The Idle Up or Stationary PTO feature cannot
be activated until the Remote PTO relinquishes control
To operate the PTO in this mode the vehicle must meet the following conditions:
Be in “park” position ( vehicles equipped with automatic transmission)
Upfitter provider (on/off) switch has been activated
Parking brake applied (vehicles equipped with manual transmission)
Clutch not depressed (clutch interlock switch)
Vehicle must be running
No transmission, engine, accelerator, brake or clutch switch faults present
PTO must be correctly installed using the vehicle provided circuits
Various features provided by the Cummins module
Single Set Speed ( sub set of remote PTO)
Single set speed allows the customer to set up the PTO to operate at a single idle speed.
This speed is “remembered” through ignition cycles or battery disconnect. The set point
can be changed unlimited times and in increments of 25 rpm’s. These are the instructions
to learn and unlearn Single Set Speed:
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LEARNING SET SPEED
NOTE: This Feature Requires Engine Calibration Software released in December
2008:
If your vehicle was produced before December 2008, you must have the dealer “Reflash”
the engine controller to December 2008 or later engine software.
In order for this feature to work the PTO MUST be wired as REMOTE PTO (pto
switch between F425 and V937) not standard PTO.







Key ON (Engine not running)
Press and release Cruise SET button 5 times within 10 seconds
Start Engine (Engine Running)
Go into IDLEUP Mode (Cruise ON then SET to go to 900 RPM)
Set the desired speed (using cruise switches)
Press Cancel
Turn key off (to save the setting)
UNLEARNING SET SPEED
 Key ON (Engine not run)
 Press and release Cruise Set button 5 times within 10 seconds.
Note: To LEARN a new speed, first UNLEARN the old speed
 Once the idle speed is LEARNED, the engine will go to that idle speed whenever
the Remote PTO switch is turned on, without additional operator assistance.
 PTO will engage first and then the idle speed will ramp up to the LEARNED
speed, thus not violating the AISIN requirement of not allowing PTO engagement
above 1000 RPM.
 The LEARNED speed is saved at power down.
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5 preset idle speeds (sub set of remote PTO)
This feature comes factory preset to the following 5 engine idle speeds 900, 1100, 1300,
1500, 1700 rpm’s. They are attained by successively toggling the PTO switch on and off,
by doing so the idle speeds will step through the preset speeds and will wrap back around
to the beginning set speed if the on/off switch is toggled enough times. These set speeds
can be changed to any speed between 900 and 2000 rpm’s using a dealer service tool.
This will give the customer the ability to have multiple idle speeds to operate his/her
equipment.
Remote Throttle and Remote Throttle Switch
This feature allows the user of a continuously variable throttle. This throttle
potentiometer is power by the 5 volt supply and sensor return lines provided.
This feature is activated when the Remote Throttle Switch is On (closed to ground) and
the main throttle is closed. Remote Throttle does not require idle validation switches and
is not to be used for main vehicle accelerator.
Accelerator interlock
This allows the accelerator to be locked out when activated. This feature is often used in
conjunction with remote PTO or remote throttle. While active it disables the vehicles
accelerator pedal typically for safety reasons.
Switched Max Operating Speed
This feature selects a lower maximum engine speed when the switch is On (closed to
ground). The lowered engine speed is can be changed.
Switch Return
Electrical return/ground for switch circuits.
J1939 Interface
Cummins provides this interface to “gate” certain CAN messages for customer use. It is
an industry standard three way connector located underhood. Messages included are
vehicle speed, engine speed, park brake on/off, system voltage – filtered, brake switch
status, clutch switch engaged, wait to start lamp status and coolant temp.
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Stationary PTO/Remote PTO Calibrations:
Maximum Engine Torque
The engine torque will be limited to this value when PTO or Remote PTO is Active.
Maximum Vehicle Speed
The maximum vehicle speed allowed before deactivating PTO. Range 1-25 MPH.
Minimum Engine Speed
Defines the lower limit engine speed can be adjusted to when PTO/Remote PTO is
active. The engine speed can be reached by either Ramp down or Bump down.
Maximum Engine Speed
Defines the upper limit engine speed can be adjusted to when PTO/Remote PTO is
active. The engine speed can be reached by either Ramp up or Bump Up.
Engine Speed Ramp Rate
The ERPM/second change rate allowed during a ramp up or ramp down.
Idle Up Set Speed
Initial engine speed when Idle up is activated.
Number of Remote PTO Speed Settings
Total number of engine speed selections available to Remote PTO feature. Range 1-5.
Remote PTO Speed Setting 1, 2, 3, 4 and 5
Individual engine speed settings available to Remote PTO feature.
.
Electrical Connection to the Vehicle
The vehicle wiring provides an easy access point to connect your PTO. There are two
locations provided for ease of interface 1) is a 8 way connector located on the left side of
the vehicle near the bell housing of the transmission and 2) is a connector located in the
cab of the vehicle. These connectors contain the circuits required to integrate the PTO to
the vehicles electrical system. The following chart is provided to assist in correctly
interfacing the PTO with the vehicle:
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PTO Circuit Definition Chart
The following chart is provided to assist in correctly interfacing the PTO with the vehicle:
Circuit
Name Type/Gauge/Color
F856
•Index
Circuit Functionality
18T - YL/PK
K400
18T - BR/VT
K128
18T - DB/LG
K129
18T - DB
K119
18T - LG/BK
K810
18T - VT/DG
F425
18T - PK
V937
18T - VT/BR
K425
20T - OR/BR
5V engine sensor feed
Description
5 volt pwr supply to the remote potentiometer
(remote's control power circuit). Supplied by
the engine controller
Usage
Remote throttle control
Remote's ground (ground to the potentiometer
of remote). Supplied by the engine controller.
accel pedal position sensor
Do not hook to other grounding location
Remote throttle control
Remote signal sent to the engine controller.
remote throttle signal
Signal from the remote's potentiometer.
Remote throttle control
On/Off switch provided by customer to "turn
on/off remote function. Remote switch closes
to ground. Connect ground side of switch to
pin #8 in this connector. Do not ground to
remote throttle switch
vehicle.
Remote throttle control
Feature selects a lower maximum engine
speed when switch is "on". Switch closes to
ground. Customer supplied switch.Connect
ground side of switch to pin #8 in this
Max operating speed
maximum operating speed switch
connector. Do not ground to vehicle.
switch
Disable accelerator control of engine by
closing an operator installed switch. This
switch closes to ground. Connect ground side
of switch to pin #8 in this connector. Do not
Customer supplied
Accelerator interlock switch
ground to vehicle.
switch
Customer supplied remote PTO on/off switch.
Switch closes to ground. Connect ground side
of switch to pin #8 in this connector. Do not
Remote PTO Switch
ground to vehicle.
Remote PTO
Electrical ground for switch circuits. Ground
returns to the engine controller. Do not hook to
Master ground for all
other grounding location. All customer
added PTO switches. Do
PTO System Return
supplied PTO switches ground to this pin.
not apply any "dirty"
(pin #8 ground)
Please make appropriate protected splice.
grounds to this location.
Circuit switches to ground using operator
installed switch. Connect ground side of
switch to pin #8 in this connector. Do not
Stationary PTO switch
ground to vehicle.
Stationary PTO
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Rear Turn/Stop Separate Control
Rear LED Detection
Detection
Trailer Tow Stop/Turn Lamp - Left
Trailer Tow Stop/Turn Lamp - Right
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6.7L Diesel with Aisin Automatic Transmission in Cab Stationary and Mobil Mode
Vehicle provided CAN
Buss communication
Transmission Controller
Diesel Engine Controller
F425(pink) – Remote Mode
K425
PTO on/off sw.
(orange /
brown) –
1 2
Standard
Mode
V937
(violet/brown)
K427
(orange/light green)
Indicator lamp
Relay Coil
F922C
(pink/yellow)
Ignition feed
20 amp max
F921
Ignition feed
F928
12V output
for PTO
PTO
Solenoid
and Pump
Ground circuit
Z914 (black)
PTO indicator
pressure switch
Notes:
- Z914
K425, V937 and F425 are circuits that can be found located under the dash
just in board of the park brake pedal
F922C and Z914 can also be found in the same area
OPTION 1 Above - K425 is used for standard stationary & mobile modes.
OPTION 2 Above - F425 is used for single set speed
All other wiring, switches, relays and other components will need to be
provided by the PTO installer. Anything in black comes with the truck
The PTO switch is assumed to be installed inside the cab
Do NOT externally ground circuit V937 to anything
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Description of Pressure Ports for the Aisin Transmission. PTO
Pressure Line to be connected only to #9 Line Main Pressure.
Location of the Pressure Plugs
Right
Right Side
Side Veiw
View(Passenger
(Passengerside)
Side)
③
②
①
⑦　⑥ ⑤　④
①
②
③
④
⑤
⑥
⑦
Torque Converter Out (to Cooler)
B1 (Brake No1) Pressure
B2 (Brake No2) Pressure
L/U (Lock Up Clutch) Pressure
LeftSide
SideVeiw
View(Driver
(Driverside)
Side)
Left
⑧
⑨
C1 (Clutch No1) Pressure
C2 (Clutch No2) Pressure
C3 (Clutch No3) Pressure
⑩
Hole Detail (All)
⑧
Lubrication
⑨
Line (Main) Pressure
⑩
Torque Converter In (from Cooler)
φ14.1
12°
45°
2.5
15
1/2-20UNF-2B
M10x1.25
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PTO Installation Alternative
In addition to the current method of PTO installation from beneath the vehicle, an
alternative method has been developed that allows the installation from above by
removing the PTO patch panel in the floor. The instructions are as follows.
1. Remove the rear package tray located behind the seat from the vehicle.
2. Unbolt the seat and move it to the rear of the cabin where the package tray was
removed.
3. Remove the sill guards (rocker panel covers) passenger side to allow the vinyl
floor mat to be lifted. They are removed by prying straight up to disengage metal
clips.
4. Lift the floor mat and fold it rearward and toward the drivers side to expose the
patch panel
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5. Remove the fasteners and sealer from around the patch panel. Cut away the sound
deadener pad to expose the transmission PTO access.
6. You are now able to install and assemble the PTO and pump through the opening.
Note: larger pumps must be inserted through the hole and moved toward the rear of
the opening before installing the PTO. The pump is then slid forward to connect to
the installed PTO.
7. To assemble, reverse the above procedure using RTV to reseal the PTO floor pan
patch panel.
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